Fuel cutoff valve

ABSTRACT

A fuel cutoff valve comprises a casing having a seal portion disposed facing a connecting passage and projecting in annular configuration towards a valve chamber; and a float mechanism having a float which rises and falls due to increasing and decreasing buoyancy according to the fuel level within the valve chamber. The float comprises a flexural depression-enabling recess situated on its upper surface at a location in opposition to the seal portion, for enabling the seat portion to undergo flexural depression when pressed by the seal portion. The casing has a regulating portion on the outside perimeter of the seal portion, for regulating the level of elastic deformation at which the seat portion elastically deforms into the flexural depression-enabling recess.

This application claims the benefit of and priority from Japanese Application No. 2006-163011 filed Jun. 13, 2006, the content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a fuel cutoff valve that is mounted on an upper wall of a fuel tank and opens and closes a connecting passage to connect the fuel tank and outside.

2. Description of the Related Art

On the upper part of a fuel tank, provided is a vaporized fuel processing device equipped with a full-fuel control valve and a fuel cutoff valve (roll over valve) connected to a canister, and by each valve being opened and closed at prescribed fuel fluid levels, air flow to outside the fuel tank is secured, and outflow of the liquid fuel to outside is prevented. The roll over valve cuts off fuel to outside at the fuel fluid level above the full tank fluid level to prevent fuel leakage such as when the vehicle is on a slope, when the vehicle is driving in slalom form, and the like.

However, in recent years, to deal with the varied and large space occupied in vehicles, flattening of fuel tanks has been studied, but with the kind of flattened fuel tank, to make the ratio of the dead space at the upper part of the fuel tank smaller, it is preferable to set the fuel fluid level at which the valve closes as high as possible. However, when the fuel fluid level during closing of the valve is set high, it is easy for the roll over valve to be immersed in fluid. Even in the case of the kind of fluid immersion, as shown in Japanese Pat. No. 3331269, known are means whereby to obtain high sealing properties, a rubber valve body is mounted on the center upper part of a float, and when the rubber valve plug is closing the connection path, the outer periphery of the rubber valve plug is flexibly deformed.

However, it is necessary for the rubber valve body to be rather thin so that the rubber valve body can undergo elastic deformation. The thin rubber valve body creates the problem of deterioration of the rubber valve body over time due to repeated elastic deformation.

SUMMARY

An advantage of some aspects of the invention is provided with a fuel cutoff valve that affords high sealing property using a flexible valve body of rubber or the like, and endowed with outstanding durability as well.

According to an aspect of the invention, the present invention is provided with a fuel cutoff valve that is mounted on an upper wall of a fuel tank, and opens and closes a connecting passage to connect the fuel tank and outside. The fuel cutoff valve comprising a casing having a valve chamber which connects the fuel tank interior to the connecting passage, and a seal portion disposed facing the connecting passage and projecting in annular configuration towards the valve chamber; and a float mechanism having a float housed within the valve chamber and which rises and falls according to a fuel level within the valve chamber, and a seat member installed on an upper portion of the float and having a seat portion formed of flexible material for opening and closing the connecting passage. The float includes a flexural depression-enabling recess situated on the upper portion of the float at a location in opposition to the seal portion for enabling the seat portion to undergo flexural depression when the seat portion is pressed by the seal portion, and the casing has a regulating portion formed on an outer circumference of the seal portion, for regulating a level of elastic deformation at which the seat portion elastically deforms into the flexural depression-enabling recess.

In a fuel tank employing the fuel cutoff valve in accordance with the present invention, when the fuel being supplied to the tank reaches a prescribed liquid level in the fuel tank, the float will rise due to buoyancy by means of fuel flowing into the valve chamber. Due to rising of the float, the seat member now closes off the connecting passage, cutting off the fuel tank from the outside and preventing fuel from spilling from the tank to the outside.

When the flexible seat member is seated on the seal portion, the portion of the seat member pressed against the seal portion undergoes elastic deformation towards the flexural depression-enabling recess on the upper surface of the float. At this time the flexural depression-enabling recess functions as a space permitting intrusion of the seat portion and producing reliable elastic deformation of the seal portion. Consequently, under pressure by the seal portion the seat portion undergoes elastic deformation producing intimate contact, so that high sealing property is achieved even when subjected to vibration of the vehicle.

With the seat portion of the seat member elastically deformed and seated on the seal portion, the upper surface of the seal member comes into abutment against the regulating portion which regulates the upward movement of the float, and thus the seat portion will not be stretched to any further extent by the seal portion. That is, the regulating portion, by means of regulating the level of elastic deformation of the seat portion, prevents the seat portion from being subjected repeatedly to high levels of elastic deformation, thus affording outstanding endurance.

In a preferred embodiment of the present invention, an arrangement wherein a plurality of the regulating portions are disposed in the circumferential direction so as to encircle the outside perimeter of the seal portion may be employed. By means of such an arrangement, the area of contact between the rubber seal member and the regulating portions may be kept small, preventing locking or sticking to the seal portion.

In another preferred embodiment of the present invention, an arrangement wherein the float comprises a valve support aperture at the axial center of the float; the seat member has a seat support portion projecting from the back surface of the seat portion; and the seat support portion is mounted on the float by inserting the seat support portion into the valve support aperture may be employed. By means of such an arrangement, the seat member can be installed on the float easily.

In yet another preferred embodiment of the present invention, the seat portion may be configured so as to contact the upper surface of the float. By means of such an arrangement, the seat portion undergoes flexural depression into the flexural depression-enabling recess produced by recessing a portion of the upper surface of the float, obviating need to provide a gap between the upper surface of the float and the seat portion of the seat member for the purpose of enabling flexural depression of the seat portion, thus avoiding bulkiness in the height direction of the float mechanism and contributing to a more compact design. Additionally, since the seat member is attached in a stable attitude in contact against the upper surface of the float, a high degree of surface accuracy of the seat portion vis-à-vis the seal portion is possible, and thus sealing property can be improved.

These and other objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view showing a fuel cutoff valve attached to the upper part of the fuel tank of an automobile in one embodiment of the present invention.

FIG. 2 is an exploded sectional view of the fuel cutoff valve.

FIG. 3 is an exploded perspective view of the float mechanism.

FIG. 4 is an enlarged sectional view of the area around the seal portion and the seat member.

FIG. 5 is a bottom view of the casing body.

FIG. 6 shows the operation of the fuel cutoff valve.

FIG. 7 shows the operation of the fuel cutoff valve during sway of the vehicle.

FIG. 8 shows fragmentary view of FIG. 7.

FIG. 9 shows the operation of the fuel cutoff valve with the vehicle inclined.

FIG. 10 shows fragmentary view of FIG. 9.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(1) General arrangement of fuel cutoff valve 10

FIG. 1 is a sectional view showing a fuel cutoff valve 10 attached to the upper part of a fuel tank FT of an automobile in one embodiment of the present invention. The fuel cutoff valve 10 is of so-called in-tank type installed in the interior of the fuel tank FT; it functions as a valve for restricting flow of fuel to the outside in the event of a rise in fuel level within the fuel tank FT when the vehicle leans or turns sharply for example. The fuel cutoff valve 10 comprises as its principal parts a casing 20, a float mechanism 50, and a spring 70. A valve mounting portion 21 is integrally formed on the upper part of the casing 20, and is attached to the inside of the fuel tank FT via a bracket BK which has been welded to the lower face of the tank upper wall FTa of the fuel tank FT.

(2) Arrangement of parts of fuel cutoff valve 10

FIG. 2 is an exploded sectional view of the fuel cutoff valve. In FIG. 2, the casing 20 comprises a casing body 30, and a base plate 35 installed on the bottom of the casing body 30. The casing body 30 comprises an upper wall 32 and a side wall 33 extending in cylindrical shape downward from the upper wall 32, forming a cup-shaped valve chamber 30S surrounded by the upper wall 32 and the side wall 33, and having a bottom opening 30 a at the bottom end. A connecting passage-forming projection 32 a is formed projecting downwardly from the center portion of the upper wall 32, and the connecting passage-forming projection 32 a is perforated by a connecting passage 32 b that connects to the valve chamber 30S, with the valve chamber 30S side of the connecting passage 32 b constituting an annular seal portion 32 c. In the upper part of the side wall 33 is formed a vent hole 33 a that connects the fuel tank FT interior with the valve chamber 30S; in the lower portion is formed a fastening claw 33 b. The fastening claw 33 b is formed for attaching the base plate 35. The base plate 35 is a component for closing the bottom opening 30 a of the casing body 30; by engaging the fastening claw 33 b of the casing body 30 with a fastening hole 35 a formed in the outside peripheral portion of the base plate 35. The base plate 35 is attached to the casing body 30 to close the bottom opening 30 a of the casing body 30. The base plate 35 is perforated by a central communicating hole 35 c and a communicating hole 35 d surrounding the communicating hole 35 c. These communicating holes 35 c, 35 d are formed so as to lie in opposition to the lower face of the float mechanism 50. A spring support portion 35 e for supporting the lower end of a spring 70 is formed on the upper face of the base plate 35.

In the upper part of the casing body 30A is formed a pipe portion 37 that projects outwardly to the side from the center. A pipe passageway 37 a is formed inside the pipe portion 37. The pipe passageway 37 a connects at a first end thereof to the valve chamber 30S via the connecting passage 32 b of the casing body 30, and at the other end to the canister side.

FIG. 3 is an exploded perspective view of the float mechanism 50. In FIG. 2 and FIG. 3, the float mechanism 50 comprises a float 51, and a seat member 55 installed on top of the float 51. The float 51 is designed with receptacle shape including an upper wall 51 a, and a side wall 51 b of tubular shape extending downwardly from the periphery of the upper wall 51 a; the interior space thereof constitutes a float chamber 51S for producing buoyancy. Eight Guide ribs 51 c are formed on the outside periphery of the float 51. The guide ribs 51 c are formed at an interval around the circumference of the side wall 51 b of the float 51, and project in rib configuration in the vertical direction.

Upper vent holes 52 a are formed in the upper wall 51 a of the float 51. The upper vent holes 52 a are formed at four locations surrounding the seat member 55. The diameter of the upper vent holes 52 a can be established from 1.5 to 3 mm. The passage length of the upper vent holes 52 a can be established from 1.5 to 2.5 mm, in consideration of the wall thickness of the upper wall 51 a of the float 51. Here, the lower limits for diameter and passage length of the upper vent holes 52 a will be established in consideration of avoiding blockage of the upper vent holes 52 a by the surface tension of the fuel; meanwhile, as will be discussed later, the upper limits thereof will be established in consideration of their function as discharge paths for vapors depending on the rate of rise in fuel level. A side communication hole 52 b is formed in the side wall 51 b of the float 51. Here, the side communication hole 52 b has a passage area greater than that of the upper vent holes 52 a, and as shall be discussed later is designed to function as a discharge path for vapors from the float chamber 51S to the valve chamber 30S.

The seat member 55 is supported in a valve support aperture 53 which is formed in the center of the upper part of the float 51. The seat member 55 is formed from flexible material (e.g. a rubber material or thermoplastic elastomer material), and comprises a disk-shaped seat portion 55 a, a seat support portion 55 b of rod shape projecting down from the center lower part of the seat portion 55 a, and a detent portion 55 c formed midway along the seat support portion 55 b. The seat support portion 55 b is press-fit into the valve support aperture 53 and attached to the upper part of the float 51 by disposing the detent portion 55 c so as to engage the peripheral edge of the valve support aperture 53.

The spring 70 is positioned within the float chamber 51S of the float 51. The spring 70 is interposed between one end of the float 51 and the spring support portion 35 e of the base plate 35, thereby urging the float 51 upward.

FIG. 4 is an enlarged sectional view of the area around the seal portion 32 c and the seat member 55. In the area around the seal portion 32 c and the seat member 55 is disposed a mechanism for inducing flexural depression of the flexible seat member 55, as well as regulating the extent of flexural depression to no more than a prescribed level. Specifically, a flexural depression-enabling recess 53S is formed on the upper part of the float 51. The flexural depression-enabling recess 53S is formed at a location in opposition to the seal portion 32 c, so as to enable the seat portion 55 a to undergo flexural depression when the seat portion 55 a pressed by the seal portion 32 c. Here, the flexural depression-enabling recess 53S is of a width such that even if the casing 20 and the float 51 are inclined relative to one another, one end of the seat portion 55 a which is the first part of the seat portion 55 a to come into abutment against the seal portion 32 c can undergo flexural depression into the flexural depression-enabling recess 53S (see FIG. 10). As shown in FIG. 3, liquid discharge slots 53Sa are formed at three locations in the circumferential direction at the outside perimeter of the flexural depression-enabling recess 53S, for discharge of fuel which has collected within the flexural depression-enabling recess 53S and facilitate flexural depression of the seat member 55.

FIG. 5 shows the seal portion 32 c formed on the upper wall 32, shown viewed from below. On the outside perimeter of the seal portion 32 c is formed a regulating portion 32 d for regulating the level of flexural depression of the seat portion 55 a. The regulating portion 32 d is divided into multiple parts (at eight locations in FIG. 5) arranged in annular configuration; as depicted in FIG. 4, the regulating portion 32 d regulates the extent of flexural depression of the seat portion 55 a by pressing the outside peripheral portion of the seat member 55.

(3) Operation of fuel cutoff valve 10

(3)-1 Operation of fuel cutoff valve 10 when large rising flow occurs

FIG. 6 shows the operation of the fuel cutoff valve 10. With the fuel tank FT close to the full tank level and the fuel cutoff valve 10 in the open state, a sudden incline of the fuel tank, or the occurrence of excess fuel vapors, may cause accumulated vapors in the upper part of the fuel tank FT to produce a rising flow which enters the valve chamber 30S through the vent hole 33 a in the side wall 33, as well as entering into the float chamber 51S of the float 51 through the basal communicating holes 35 c, 35 d of the base plate 35, with the vapors subsequently passing through the side communication hole 52 b and escaping through the gap between the outside periphery of the float 51 and the inside wall of the casing body 30, and thence escaping from this gap through the connecting passage 32 b and the pipe passageway 37 a, and towards the canister end. At this same time, since the vapor flow entering the float chamber 51S of the float 51 escapes from the side communication hole 52 b, a high level of force that would cause the float 51 to rise does not develop; and since the passage area of the connecting passage 32 b is smaller than the passage area of the side communication hole 52 b, the rising force of the float 51 is held in check by a rise in pressure in the upper part of the valve chamber 30S. Consequently, if large rising flow should occur, the fuel cutoff valve 10 will ensure venting of vapors to the outside, without the fuel tank FT becoming blocked off.

(3)-2 Operation of fuel cutoff valve 1 during sway of vehicle

FIG. 7 shows the operation of the fuel cutoff valve 10 during sway of the vehicle. With the fuel level at a location close to full tank level, in the event that the fuel tank FT should sway due to sudden turning of the vehicle, the liquid level within the fuel tank FT will surge as shown by the double-dot and dash line in FIG. 7. The fuel will flow into the float chamber 51S of the float 51 via the basal communicating holes 35 c, 35 d of the base plate 35. At this time, due to the rapid rate of rise of the fuel level in combination with the small amount of vapors escaping through the upper vent hole 52 a of the float, the buoyancy created by the vapors collecting within the float chamber 51S becomes appreciable. When the fuel level in the float chamber 51S reaches a certain height h2 and the buoyancy and upward force of the spring 70 overcome the weight of the float 51, the float 51 bobs upward. Due to rising of the float 51 the seat member 55 now becomes seated in the seal portion 32 c and closes off the connecting passage 32 b. Thus, the fuel can be prevented from flowing out from the fuel tank FT during sharp turning of the vehicle. As shown in FIG. 8, in this closed state, when the rubber seat member 55 becomes seated against the seal portion 32 c, the portion pressed by the seal portion 32 c undergoes elastic deformation towards the flexural depression-enabling recess 53S on the upper part of the float 51. Consequently, the seat portion 55 a, under pressure by the small-diameter seal portion 32 c, undergoes flexural depression so as to come into intimate contact with it. Then, once the regulating portion 32 d comes into abutment against the seat portion 55 a, further flexural depression by the seat portion 55 a is regulated.

(3)-3 Operation of fuel cutoff valve 1 with the vehicle inclined

FIG. 9 shows the operation of the fuel cutoff valve 10 with the vehicle inclined. If the one wheel of the vehicle should ride up over the curb, or if the vehicle should incline on a sloping roadway such as hill, a gradual rise in fuel level in the fuel tank FT will be produced. When the fuel level reaches the fuel cutoff valve 10 and then rises further, the fuel will flow into the valve chamber 30S through the basal communication holes 35 c, 35 d in the base plate 35. Since the rate of rise of the fuel level at this time is not particularly fast, despite the rise in fuel level, vapors within the float chamber 51S will be discharged through the upper vent hole 52 a, and the fuel will flow into the float chamber 51S without rising of the float 51. Then, as the fuel level exceeds a prescribed level and reaches a certain height h1 within the float chamber 51S of the float 51, the float 51 will rise due to the buoyancy thereof, whereupon the seat portion 55 a of the seat member 55 becomes seated in the seal portion 32 c and closes off the connecting passage 32 b. As shown in FIG. 10, even if the float 51 should become seated in an inclined state on the seal portion 32 c at this time, high sealing property will be attained due to elastic deformation of the seat portion 55 a in response to the seal portion 32 c. Moreover, since the flexural depression-enabling recess 53S has been designed with a width such that even if the casing 20 and the float 51 are inclined relative to one another, one end of the seat portion 55 a (the portion at right in the drawing) initially comes into abutment against the seal portion 32 c, one end of the seat portion 55 a can undergo flexural depression into the flexural depression-enabling recess 53S. Then, when the fuel level in the fuel tank FT drops, the float 51 declines in buoyancy and descends, opening up the connecting passage 32 b.

(4) Operation and Effects of the Embodiment

The constitution of the embodiment discussed above affords the following effects.

(4)-1 As depicted in FIG. 8, when the rubber seat member 55 is seated on the seal portion 32 c, the portion pressed by the seal portion 32 c undergoes elastic deformation towards the interior of the flexural depression-enabling recess 53S in the upper portion of the float 51. The flexural depression-enabling recess 53S is formed with inside diameter larger than the outside diameter of the seal portion 32 c, and at this time functions as a space to enabling the seal portion 32 c to enter, reliably bringing about elastic deformation of the seat portion 55 a. Consequently, under pressure by the small-diameter seal portion 32 c the seat portion 55 a undergoes elastic deformation producing intimate contact, so that high sealing property is achieved even when subjected to vibration of the vehicle.

(4)-2 As depicted in FIG. 10, even if the float mechanism 50 should become seated with the seat portion 55 a in an inclined state on the seal portion 32 c, high sealing property will be attained due to elastic deformation of the seat portion 55 a in response to the seal portion 32 c. Moreover, since the flexural depression-enabling recess 53S has been designed with a width such that even if the casing 20 and the float 51 are inclined relative to one another, one end of the seat portion 55 a initially comes into abutment against the seal portion 32 c, one end of the seat portion 55 a can undergo flexural depression into the flexural depression-enabling recess 53S.

(4)-3 With the seat portion 55 a of the seat member 55 elastically deformed and seated on the seal portion 32 c, the upper surface of the seat portion 55 a comes into abutment against the regulating portion 32 d regulating the upward movement of the float 51, and thus the seat portion 55 a will not be stretched to any further extent by the seal portion 32 c. That is, the regulating portion 32 d, by means of regulating the level of elastic deformation of the seat portion 55 a, prevents the seat portion 55 a from being subjected repeatedly to high levels of elastic deformation, thus affording outstanding endurance, as well as preventing the seat portion 55 a from damage by being clamped between the floor of the flexural depression-enabling recess 53S and the seal portion 32 c.

(4)-4 As depicted in FIG. 5, since the regulating portions 32 d are disposed at an interval in the circumferential direction about the seal portion 32 c, the area of contact between the rubber seat member 55 and the regulating portions 32 d may be kept small, preventing locking or sticking.

(4)-5 Simply by inserting the seat support portion 55 b into the valve support aperture 53, the seat member 55 can be easily mounted onto the float 51 and detained by the detent portion 55 c.

(4)-6 Since the seat portion 55 a undergoes flexural depression into the flexural depression-enabling recess 53S produced by recessing a portion of the upper surface of the float 51, obviating the need to provide a gap between the upper surface of the float 51 and the seat portion 55 a for the purpose of enabling flexural depression, bulkiness in the height direction of the float mechanism 50 can be avoided, contributing to a more compact design.

(4)-7 Since the seat member 55 is attached to the float 51 in a stable attitude in contact against the upper surface of the float 51, a high degree of surface accuracy of the seal face of the seat portion 55 a against the seal portion 32 c is possible, and thus sealing property can be improved.

The invention is not limited to the preceding embodiment, and can be reduced to practice in various other forms without departing from the spirit thereof. For example, the following modifications are possible.

In the preceding embodiment, the fuel cutoff valve was installed on the inside of the fuel tank, i.e. a so-called in-tank design, but is not limited thereto and may be adapted as well to arrangements wherein the valve is welded to the upper face of the upper wall of the fuel tank, with its bottom part being inserted through a mounting hole.

The foregoing detailed description of the invention has been provided for the purpose of explaining the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use contemplated. The foregoing detailed description is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Modifications and equivalents will be apparent to practitioners skilled in this art and are encompassed within the spirit and scope of the appended claims. 

1. A fuel cutoff valve that is mounted on an upper wall of a fuel tank and opens and closes a connecting passage to connect the fuel tank and outside, the fuel cutoff valve comprising: a casing having (i) a valve chamber which connects the fuel tank interior to the connecting passage, and (ii) a seal portion disposed facing the connecting passage and projecting in annular configuration towards the valve chamber; and a float mechanism having (i) a float that is housed within the valve chamber and rises and falls according to a fuel level within the valve chamber, and (ii) a seat member that is installed on an upper portion of the float and has a seat portion formed of flexible material for opening and closing the connecting passage, wherein the float includes a flexural depression-enabling recess situated on the upper portion of the float at a location in opposition to the seal portion for enabling the seat portion to undergo flexural depression when the seat portion is pressed by the seal portion, and the casing has a regulating portion formed on an outer circumference of the seal portion, for regulating a level of elastic deformation at which the seat portion elastically deforms into the flexural depression-enabling recess.
 2. The fuel cutoff valve in accordance with claim 1, wherein the regulating portion includes a plurality of projections that are disposed to encircle an outer circumference of the seal portion.
 3. The fuel cutoff valve in accordance with claim 2, wherein the projections are disposed at an interval and in the circumferential direction about the seal portion.
 4. The fuel cutoff valve in accordance with claim 1, wherein the float includes a valve support aperture at an axial center of the float, and the seat member includes a seat support portion projecting from a back surface of the seat portion, the seat support portion being configured to be mounted on the float by being inserted into the valve support aperture.
 5. The fuel cutoff valve in accordance with claim 1, wherein the seat portion is configured to contact an upper surface of the float.
 6. The fuel cutoff valve in accordance with claim 1, wherein the float includes a liquid discharge slot that is formed at the outside perimeter of the flexural depression-enabling recess, the liquid discharge slot being configured to discharge fuel collected within the flexural depression-enabling recess to outside of the float. 